Starch-emulsifier composition and methods of making

ABSTRACT

A method of producing starch-emulsifier compositions by heating a starch in the presence of an emulsifier to form a complex with unique properties. The product can be further treated to obtain greater than about 20% short chain amylose. Starch-emulsifier compositions (e.g., powders, gels, pastes) produced by this method and food products containing the starch-emulsifier composition are also described.

RELATED APPLICATIONS

This is a Continuation application of U.S. Ser. No. 09/082,345, filedMay 20, 1998, now U.S. Pat. No. 6,017,388, which is aContinuation-in-Part of U.S. Ser. No. 08/783,574, filed Jan. 15, 1997(U.S. Pat. No. 5,755,890, issued May 26, 1998), which claims priority toProvisional Application No. 60/010,061, filed on Jan. 16, 1996. Theentire teachings of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Starch is composed primarily of two components: amylose, a mainly linearpolymer of about 500-6000 α-D glucosyl residues, and amylopectin, ahighly branched polymer of α-D glucosyl distributed in 15-60 residuesper chain (Godet et al., Carbohydrate Polymiers 27:47-52 (1995)). It iswell known that amylose can form complexes with molecules such asiodine, alcohols and lipids, whereas amylopectin forms these complexesweakly or not at all (Morrison et al., Cereal Chem 70:385-91 (1993);Sarko & Zugenmaier, Fiber Diffractiont Methods, A. D. French & K. C.Gardner, Eds., ACS Symposium Series 141:459-482 (1980)). The in situbiosynthesis of amylose-lipid complexes in starch with naturallyoccurring fatty acids and phospholipids has been demonstrated (Morrisonet al. (1993)). Others have shown that complex formation occurs duringheat/moisture treatments, especially during gelatinization of starcheswith the naturally containing lipids (Kugimiya et al., Stärke 32:265-270(1980); Kugimiya & Donovan, J. Food Sci. 46:765-777 (1981)) or whenlipids are added to defatted starches (Biliaderis et al., Food Chem.22:279-295 (1986)) or pure amylose which is free of natural lipids(Biliaderis et al, Carbohydr. Polym. 5:367-389 (1985)).

Both naturally-occurring and heat-formed complexes show specificproperties such as a decrease in amylose solubility or an increase ingelatinization temperatures (Eliasson et al., Stärke 33:130 (1981),Morrison et al. (1993)). Polar lipids, e.g., fatty acids and theirmonoglyceride esters are of technological importance in starch systems,as they cause a reduction in stickiness, improved freeze-thaw stability(Mercier et al., Cereal Chem. 57:4-9 (1980) and retardation ofretrogradation. One important example is the use of fatty acids andmonoglycerides as anti-stating agents in bread and biscuits.Incorporation of such additives in the dough induces a slowercrystallization (retrogradation) of the amylose fraction and retards thestaling of bread (Krog, Stärke 22:206-210 (1971)).

SUMMARY OF THE INVENTION

The present invention pertains to starch-emulsifier compositions andmethods of making the starch-emulsifier compositions comprisin heatingstarch (e.g., jet-cooking, heating in a batch cooker) in the presence ofan emulsifier to produce a starch-emulsifier dispersion which canoptionally be treated to obtain greater than about 20% by weight shortchain amylose.

In one embodiment of the invention, a starch and an emulsifier areheated (e.g., jet-cooked) to disrupt essentially all starch granules andsolubilize amylose and amylopectin in the starch. The product contains adispersion of gelatinized starch and emulsifier which is believed to bein the form of a complex, as seen by X-ray diffraction. The dispersionof starch and emulsifier can be cooled slowly or quickly to fonn anelastic textured paste, or the solution can optionally be dried to apowder.

In another embodiment of the invention, a starch and emulsifier areheated (e.g., jet-cooked) to produce a dispersion of gelatinized starchand emulsifier in which the amylose and amylopectin are solubilized. Thestarch is subsequently hydrolyzed to release short chain amylose,preferably using an enzymatic treatment. After hydrolysis of thestarch-emulsifier solution, the solution can optionally be heated to atemperature sufficient to liquify the emulsifier, thereby increasing thepercentage of starch-emulsifer complex formed. Thereafter, the solutioncan be cooled to form a short-textured, non-elastic paste or it canoptionally be dried (e.g., by spray drying) into a powder.

The starch-emulsifier compositions can also be optionally co-processedwith hydrocolloids, polymers, gums, modified starches and combinationsthereof, which can be added at any point in the processes describedherein. These optional ingredients serve to change (e.g., increase ordecrease) the functional properties (e.g., water binding capacity, oilbinding capacity or viscosity) of the composition depending upon productend use. For example, these optional ingredients can be added toincrease the overall water binding capacity of the starch-emulsifiercomposition or change the rheology of the starch-emulsifier composition.

The starch-emulsifier composition produced by a process which uses ahydrolytic method is characterized by a relatively small particle size(a weight average of 4-5 μ), a short, non-elastic texture or rheologyand a low water and oil binding capacity. The starch-emulsifiercomposition produced by cooking starch and emulsifier, withoutsubsequent hydrolysis, is characterized as more elastic and a lessopaque gel compared to the hydrolyzed product. In either process, thedried starch-emulsifier composition can be rehydrated, preferably in anaqueous medium suitable for use in food or beverage fonnulations (e.g.,milk or water), under conditions of medium to high shear to produce anopaque paste upon refrigeration.

The starch-emulsifier compositions produced by the methods describedherein are useful in a variety of food and beverage applications. Forexample, the starch-emulsifier compositions can be used as an opacifierin foods and beverages such as skim milk, or as a texturizing agent toprepare dairy products with a rheology similar to sour cream, yogurt,mayonnaise and similar products. For example, the starch-emulsifiercompositions of the present invention can be used to preparelactose-free dairy products. The starch-emulsifier compositions can alsobe used to stabilize foams, such as in the production of ice cream, andas a fat replacer in a variety of reduced-fat and fat-free foods, suchas cakes, pudding type desserts, sauces, mriargarine, cream cheese andother spreads, snack dips, mayonnaise, sour cream, yogurt, ice cream,frozen desserts, fudge and other confections, and skim milk. Thestarch-emulsifier compositions can be incorporated into fat-free,reduced fat and fat containing cheeses, such as natural, processed andimitation cheeses in a variety of forms (e.g., shredded, block, slices,grated). The starch-emulsifier compositions are also useful, as forexample a shortening, in baked goods such as cakes, pies, brownies,cookies, breads, noodles, snack items, such as crackers, graham crackersand pretzels, and similar products.

DETAILED DESCRIPTION OF THE INVENTION

The present invention pertains to methods of manufacture and thestarch-emulsifier compositions produced thereby that are useful in avariety of food and beverage applications. According to the invention, astarch is heated in the presence of an emulsifier to a temperature andpressure sufficient to disrupt essentially all the starch granules andsolubilize the amylose and amylopectin contained therein, such as by jetcooking, to yield a starch-emulsifier dispersion. This dispersion can becooled slowly or quickly to form an elastic gel, or the dispersion canoptionally be dried to a powder. The powder can be rehydrated withmedium to high shear to produce a smooth gel that is more elastic andless opaque compared to the hydrolyzed product described below.

Alternatively, a dispersion of the starch-emulsifier complex produced asdescribed above can be treated to generate about 20% by weight shortchain amylose (e.g., enzymatically debranched, hydrolysis of thebackbone by amylase or acid hydrolysis), and the resultant dispersion ofstarch, containing greater than about 20% by weight short chain amylose,and emulsifier is optionally heated to a temperature sufficient toinactivate the enzyme if used and to liquify the emulsifier.Liquification of the emulsifier facilitates the formation of additionalstarch-emulsifier complexes in the final composition.

As used herein, short chain amylose is defined as amylose having adegree of polymerization (DP) of from about 6 to about 60 and atmolecular weight of from about 1,000 to about 10,000 which is indicativeof maltodextrin. The term “gelatinization” or varient thereof, isintended to embrace the generally recognized term but also is intendedto encompass the process of rupturing essentially all starch granulespresent in the starch, thereby releasing amylose and amylopectin.

The dispersion of starch and emulsifier containing about 20% short chainamylose can be allowed to cool to form an opaque paste with a short,non-elastic texture. Alternatively, the dispersion can be dried to apowder and rehydrated with medium to high shear to produce a short,smooth, nonelastic textured paste of high opacity upon refrigeration.

The starch used as a starting material in the process of the presentinvention can be a native starch or a pregelatinized starch. If apregelatinized starch is utilized, it should preferably contain a lowamount of resistant starch, such as less than about 10% resistantstarch. If the starting starch has more than about 10% resistant starch,the starch can be used in the present invention if it is first leated toa temperature above the melting point of the resistant starch.

The native or pregclatinized starch used in the present invention shouldpreferably have an amylose content of less than about 30%. If theamylose content is greater than about 30%, debranching and/or hydrolysisof the starch (e.g., with an acid or by enzymatic amylase treatment)prior to heating in the presence of the emulsifier may be required toreduce the molecular weight of the amylose. The use of high-amylosestarch is generally not preferred, as high-amylose starch tends to formstable resistant starch with a large particle size during processing.For example, debranched or partially hydrolyzed amylomaize can be used,as well as common cornstarch, potato, tapioca, wheat, smooth pea, rice,sago, barley and oat starches.

Without wishing to be bound by theory, it is believed that the processesdescribed herein yield compositions comprising starch and emulsifier inthe form of a complex having an insoluble microparticle nature which isstabilized by the interaction between amylose and emulsifier. Thecomposition also comprises uncomplexed emulsifier, uncomplexed starch,and optionally short chain amylose if debranching and/or hydrolysis isperformed. Thus, emulsifiers capable of forming a complex with amyloseare particularly preferred for use in the invention. Generally, theemulsifiers will be monoglycerides, sorbitan esters, diacetyl tartaricacid esters of monoglycerides (DATEM), propylene glycol esters, enzymemodified lecithin (EML), polysorbates and sucrose esters of medium andlong chain saturated fatly acids (e.g., having an acyl group containingmore than about 10 carbon atoms), as well as saturated fatty acids(e.g., saturated fatty acids which contain from about 12 to about 18carbons) and unsaturated fatty acids (unsaturated fatty acids whichcontain from about 12 to about 18 carbons, e.g., oleic and linoleicacids). For example, emulsifiers including, but not limited to,polyethylene glycol monolaurate or glyceryl monostearate, sodium orcalcium stearoyl-2-lactylate, polyoxyethylcne sorbitan monostearate,sucrose monostearate and sucrose monopalmitate are suitable for use inthe starch-emulsifier composition of the present invention, as well asother saturated fatty acids (see also Example 6). EML can be produced bytreating lecithin with phospholipase A2. EML produced through the actionof phospholipase A2 is enriched in lysophosphatydylcholine, which isknown to form complex with amylose. Commercial EML is available at LucasMeyer Inc. (Decatur, Ill.) and Central Soya Co. (Fort Wayne, Ind.).

The starch and the emulsifier are combined in an aqueous medium such aswater to produce a dispersion. The dispersion generally contains fromabout 5% to about 25% (w/w) of starch. The emulsifier will be present inan amount which is approximately 0.1% to about 25% of the starch weight,and more preferably 1% to 10% of the starch weight present in thecomposition. The dispersion is then heated under conditions appropriateto disrupt essentially all the starch granules and solubilize theamylose and amylopectin present in the starch. This can be carried out,for example, by co-jet cooking the starch-emulsifier dispersion.Alternatively, the starch-emulsifier dispersion can be heated in areactor or batch cooker, or by any other method in which the starch isgelatinized in the presence of the emulsifier, such as by extrusion. Thestarch can also be jet cooked into the emulsifier; that is, the starchcan be heated to or above its gelatinization temperature and immediatelycombined with the emulsifier. The emulsifier may need to be dispersedbeforehand in a little water and the dispersion added to the starchslurry prior to cooking; added to the jet cooked starch; or the starchis jet cooked into the dispersion of the emulsifier. The temperature andpH necessary to disperse the emulsifier in water are characteristic foreach emulsifier or can be determined by those skilled in the art. It isessential that the emulsifier and starch be combined prior to theheating or jet cooking step or immediately after solubilization of thestarch, as later addition of the emulsifier results in a larger particlesize and a gritty product due to retrogradation of the starch.

In one embodiment, after the starch-emulsifier dispersion is heated tosolubilize the amylose present in the starch, the starch is treated torelease short chain amylose. Appropriate treatment of the starch willresult in a starch material containing greater than about 20% shortchain amylose. Generally, release of the short chain amylose from thestarch will be carried out by enzymatically dzbranching the starch,e.g., the starch can be debranched with (1-6)-specific glycosid enzymeswhich are capable of cleaving 1,6-alpha-D-glucosidic linkages. Forinstan(c, the starch-emulsifier dispersion can be treated withpullulanase or isoamylase, at a temperature and pH and for a timesufficient to allow the enzyme to release the short chain amylose.Generally, appropriate temperatures will range from about 25° C. toabout 100° C., with from about 55° C. to about 65° C. being preferred,for a time of from about 1 hour to about 30 hours, depending on theenzyme utilized and the enzyme concentration. Furthermore, the pH of thesolution will be from about 3 to about 7.5. In 2 particularly preferredmethod, the starch-emulsifier dispersion is treated with pullulanase at60° C. at pH 5 for about 4 hours. The optimum conditions for theenzymatic reaction will vary, with changes in parameters such as starchand enzyme concentrations, pH, temperature and other factors which canbe readily determined by the skilled artisan.

Alternatively, the starch can be randomly hydrolyzed to produce greaterthan 20% short chain amylose by use of an appropriate acid. such as amineral acid or organic acid. Generally, acid hydrolysis will take placeat a pH of less than about 4° C. and at a temperature greater than about60° C., depending upon the acid used. The conditions for acid hydrolysisshould be such that inappropriate side reactions are minimized. Shortchain amylose can also be generated by treating the starch with alphaamylase, alone or in combination with pullulanase. Substantialdebranching or hydrolysis of the starch (c.g., debranching sufficient togenerate a starch material containing greater than about 20% short chainamylose) results in a short textured, non-elastic paste, whereas in theabsence of debranching or hydrolysis the product is an elastic gel (seeExample 3).

Both the hydrolyzed and non-hydrolyzed starch-emulsifier dispersions canbe heated to a temperature and pH and for a time sufficient to liquifythe emulsifier, i.e., a temperature above the melting point of theemulsifier, to produce additional starch-emulsifier complexes in thecomposition. If a debranching enzyme is used, the heat treatment willalso inactivate the enzyme. In most cases, a temperature ofapproximately 70° C. to approximately 100° C. is sufficient to liquifythe emulsifier within the dispersion and inactivate the enzyme, ifpresent. The starch-emulsifier dispersion can be heated by a number ofconventional methods, including a heat exchanger, jacketed reactor,direct steam injection or evtrudcr.

The starch-emulsifier compositions that have be2en hydrolyzed andsubsequently heat treated appear watery and have a low viscosity atapproximately 10% to 25% solids. The low viscosity product can be cooledslowly or rapidly to fon a paste for use in food applications, or thelow viscosity composition can be optionally dried to produce a powder bya number of art-recognized methods, including spray drying, belt drying,freeze drying, drum drying or flash drying; however, in a preferredembodiment, the dispersion is spray dried. The powder can be stored atroom temperature, and can be rehydrated with water or another aqueousmedium, preferably an aqueous medium which is appropriate for use infood and beverage fonrulations, under conditions of medium to high shearto give a paste of high opacity and short, non-elastic texture.

The starch and emulsifier can also be co-processed with hydrocolloids,gums, polymers, modified starches and combinations thereof to change therheology or increase the water binding capacity of the starch-emulsifiercompositions. For example, xanthan gum, alginate, carrageenan,carboxymethyl cellulose, methyl cellulose, guar gum, gum arabic, locustbean gum and combinations thereof can be added to the starch-emulsifiercompositions at any time during the preparation thereof, as long as theadditional ingredient(s) does not prevent the formation of theamylose-emulsifier complex. That is, these additional optionalingredients can be jet-cooked along with the starch and emulsifier,added prior to or after the debranching step, added prior to or afterthe optional heating step, added to the paste composition or dry blendedwith the powdered composition after drying. Preferably, thehydrocolloid, gum, modified starch or polymer is added to the dispersionafter the debranching step and prior to drying the composition (seeExample 7) or is dry blended with the powdered composition after thedrying step.

The starch-emulsifier compositions of this invention comprisestarch-emulsifier complexes, uncomplexed emulsifier, uncomplexed starchand optionally greater than from about 20% short chain amylose if theuncomplexed starch in the composition is hydrolyzed. The percentage ofcomplex present in the composition will vary depending upon whether thestarch and emulsifier are hydrolyzed., but in any event, the compositionshould comprise a minimum of about 20% by weight starch-emulsifiercomplex. The complexes are insoluble microparticulates which have anaverage particle size of less than about 10μ, and preferably less thanabout 6μ. The starch-emulsifier composition of the present inventionproduced using hydrolysis has a short, non-elastic texture or rheologyand a low water and oil binding capacity and contains greater than about20% short chain amylose. The starch-emulsificr composition produced bycooking starch and emulsifier, without subsequent hydrolysis, ischaracterized as a more elastic and less opaque gel compared to thehydrolyzed product.

The starch-emulsifier compositions of the present invention are suitablefor use in a variety of foods and beverages. The amount ofstarch-emulsifier composition incorporated into the food or beveragewill depend upon the formulation of the food, but will generally beapproximately 1-10% by weight. For example, the starch-emulsifiercompositions can be used as an opacifier in milk and similar foods toimprove the visual appeal of the food. The starch-emulsifiercompositions can also be used as a texturizing agent in various dairyfoods; due to its small particle size, the starch-emulsifiercompositions do not impart a gritty mouthfeel to products in which it isincorporated. The starch-emulsifier compositions are useful forpreparing dairy products with a rheology similar to traditional sourcream, yogurt and mayonnaise formulations. For example, thestarch-emulsifier compositions can be used in the preparation oflactose-free dairy products. The compositions are particularly usefulfor the preparation of reduced-fat and fat-free food products,particularly mai-garines, pudding type desserts, sauces, snack dips,mayonnaise, sour cream, yogurt, ice cream, frozen desserts, cream cheeseand other spreads, fudge and other confections, and skim milk. Thestarch-emulsifier compositions can be incorporated into fat-free,reduced fat and fat containing cheeses, such as natural, processed andimitation cheeses in a variety of forms (c.g., shredded, block, slices,grated). The starch-emulsifier compositions are also useful in bakedgoods such as breads, cakes, pies, brownies, cookies, noodles, snackitems, such as crackers, graham crackers and pretzels, and similarproducts, as it does not interfere with the organoleptic properties ofthe foods in which it is incorporated.

Terms used herein have their art-recognized meaning unless otherwisedefined.

The teachings of references referred to herein are incorporated hereinby reference. All percentages are by weight unless otherwise specified.

The following examples are offered for the purpose of illustrating thepresent invention and are not to be construed to limit the scope of thepresent invention:

EXAMPLES Example 1

Effect of Different Levels of Monoglyceride on Starch-EmulsifierComposition

Fifteen gallons (55 liters) of corn starch slurry (I15% solids) andvarious levels of distilled monoglyceride emulsifier (Myverol 18-06,Quest International; containing 90% glyceryl monostearate) werepreheated to 60° C. in a Likwifier. The slurries were then pumpedthrough a jet cooker operating at 150° C. and 120 psi steam pressure.Each jet cooked dispersion was then cooled to 60° C. and the pH wasadjusted to 5.2±0.2 using 15% phosphoric acid. The starch-emulsifierdispersion was enzymatically debranched by the enzyme pullulanase(Promozymc 200 L, Novo Nordisk A/S, Denmark; 0.02 ml enzyme per gram ofstarch solids) at 60° C. for 4 hours. The debranched starch product wasthen heated to 90° C. and spray dried into a fine powvder. The spraydrier air inlet and outlet temperatures were typically 360° F. (182° C.)and 220° F. (104° C.), respectively. Four samples were prepared asdescribed above with different monoglyceride contents:

Sample A: no monoglyceride added

Sample B: 1% (of starch weight) monoglyceride added

Sample C: 3% (of starch weight) monoglyccride added

Sample D: 6% (of starch weight) monoglyceride added.

Example 2

Characterization of the Starch-Emulsifier Composition

The four samples prepared according to example 1 were analyzed bydifferential scanning calorimeter (DSC), molecular weight distribution,X-ray diffraction analysis, particle size distribution, gel viscosity,and opacity.

A. DSC Thermal Analysis

Ten milligrams of powdered sample was weighed in a Perkin Elmer highpressure capsule DSC pan. The sample was mixed with 50 μl deionizedwater and hermetically scaled in the DSC pan. The sample was thenanalyzed (DSC 7, Perkin-Elmer, Norwalk, Conn.) from 20° C. to 160° C. at10C/mirtutc with a sealed empty pan as a reference. Samples B, C. and Dshowed an endothermic peak at about 105° C., typical of the melting ofamylose-lipid complexes.

After the initial scan the samples were quench cooled from 160° C. to20° C. in the DSC., followed by reseanning from 20° C. to 160° C. at 10°C./min. Samples B, C. and D all showed a peak near 100° C. to 102° C.upon rescanning, confirming the presence of amylose-lipid complex.

B. Molecular Weight Distribution

The molecular weight distributions of the debranched samples wereanalyzed by high performance size-exclusion chromatography (HPSEC). TwoPolymer Laboratory mixed bed B columns (300×7.5 mm) were connected inseries and the temperature of the column maintained at 70° C. The mobilephase was 5 mM sodium nitrate in DMSO at a flow rate of 1 ml/minute. AWaters 400 refractive index detector was used. The columns werecalibrated using pullulan standards (Hayashibara Biochemicals, Japan)with molecular weights ranging from 5800 to 1.66×10⁴ daltons. Themolecular weights of the starch samples were obtained using PertkinElmer's Turbochrome 4 software and the calibration curve for thestandards. The starch samples (10 mg) were completely dissolved in 4 mlmobile phase by heating in a 90° C. water bath for 10 minutes. A 200 μlsample was injected onto the colunins. In general the chromatograms ofthe 4 samples prepared according to Example 1 can be divided into twofractions: nigh molecular weight (HMW) and low molecular weight (LMW).The molecular weight distribution data are summarized in Table 1. Theresults indicate that the molecular weight distributions wereessentially the same for the four samples.

TABLE 1 HMW LMW % area of Sample Mw Mn Mw Mn LMW A 470 kd 114 kd 3.7 kd2.5 kd 35 B 582 kd 119 kd 3.7 kd 2.5 kd 35 C 569 kd 119 kd 3.6 kd 2.5 kd37 D 579 kd 109 kd 3.6 kd 2.5 kd 34

C. X-ray Diffraction Analysis

X-ray diffraction diagrams of samples A, C. (as described in Example 1)and a dry blend of sample A with 3% monoglyceridc (based on starchweight, Myverol 18-06, Quest International) were recorded using a X-raydiffrictometer (Philips Electronic Instruments) with CuKα1 radiation(0.15405 nm). The generator was operated at 40 KV and 30 mA. The scanswere recorded from 2 to 30° 2-theta at a rate of 1° per minute. Scansfor sample A and the dry blend with monoglyceride were virtuallyidentical, showing mostly amorphous patterns. The scan for sample C.showed 3 distinctive peaks near 7.36, 13.1, and 20.1° 2-theta,characteristic of the crystalline patterns for amylose-lipid complex asreported by Biliaderis and Seneviratne (Carbohydrate Polymier,13:185-206 1990).

D. Particle Size Distribution

The particle size distribution was determined by using a laser lightparticle size analyzer (Microtrac, Leeds and Northrup Instruments, NorthWales, Pa.). A 15% (w/w) dispersion of each starch sample was preparedby mixing the sample in 70° C. deionized water using a kitchen blenderat high speed for 5 minutes. After cooling to room temperature, analiquot of the dispersion was analyzed. Table 2 shows the particle sizesof the samples, prepared according to Example 1, at 50 and 90percentiles. The addition of emulsifier dramatically decreased theparticle size of debranched cornstarch. However there appears to be nocorrelation between the amount of emulsifier and the particle size.

TABLE 2 Particle size (μ) Sample 50% 90% A 22.4 36.2 B 4.4 10.3 C 5.411.2 D 4.5 10.5

E. Viscosity

The viscosity of the hydrated starch samples were measured using aBohlin Visco 88, Bohlin Reologi AB, Lund, Sweden. A 15% (w/w) dispersionof each starch sample (prepared according to Example 1) was prepared bymixing the starch sample in 70° C. deionized water using a kitchenblender at high speed for 5 minutes. The dispersion was refrigerated at4° C. for 24 hours. The viscosity of the debranched cornstarch decreasedwith increasing emulsifier concentrations. The samples showed shearthinning behavior. No data was obtained for the sample withoutemulsifier (sample A) because the gel was too rigid to be measured bythis instrumental technique.

TABLE 3 Sample Viscosity (Pas) at 17.5s⁻¹ B 3.75 C 1.37 D 0.24

F. Opacity

Opacity of the above dispersions after a series of dilution was measuredby a spectrocolorimcter (ColorQuest 45/0, Hunter Associates Laboratory,Reston, Va.). An opacity of 100% is equivalent to the opacity of thewhite tile used as a reference. At the same solids level, opacityincreased with increasing emulsifier concentrations up to 3%. Theopacity of the sample containing 6% emulsifier (D) was marginally, if atall, higher than the 3% sample (C).

Example 3

Effect of Debranching the Starch

A 15% cornstarch slurry containing 3% (by weight of starch) glycerylmonostearatc was jet cooked as described in Example 1. The jet cookedmaterial was split into two batches; one batch was enzymaticallydebranched using pullulanase as described in Example 1, whereas theother batch was not treated with the enzyme. After refrigeration the twosamples were examined for differences in gel appearance and rheology.The debranched sample formed an opaque paste. The rheology of the pastewas short and smooth, resembling that of CRISCO® brand shortening. Incontrast, the sample which was not debranched gave a more elastic andless opaque gel compared to the debranched sample, resembling that ofjello. The sample which was not debranched had no low molecular weightfraction and its high molecular weight fraction comprises an Mw of 7359kd and an Mn of 294 kd. The particle size of this sample at 50% wasapproximately 4.5μ and at 90% was approximately 10.5μ.

Example 4

Effect of Processing Conditions

A dry blend of 75 grams of debranched cornstarch (Example 1, sample A)and 2.25 grams of glyceryl monostearate was dispersed in 125 grams of90° C. water by mixing in a kitchen blender at high speed for 5minutes;. The dispersion was split into two batches. One batch wasrefrigerated at 4° C. and the other batch was autoclaved at 121° C. for10 minutes before being refrigerated. Both samples remained liquid after24 hours of refrigeration and gave a gritty mouthfeel when judged by asensory panel. Thus, neither process produced a satisfactory product foruse in food products.

Example 5

Addition of Emulsifier After Jet Cooking the Starch

A cornstarch slurry (15% solids) containing monoglyceride (2% by weightof starch, Myverol 18-06, Quest International, containing 90% glycerylmonostearate) was jet cooked and processed as described in Example 1(sample 5A). Another sample (sample 5B) was prepared by jet cookingcornstarch slurry (15% solids) directly into a predispersedmonoglyceridc dispersion (2% glyceryl mionostcaratc, by weight ofstarch) followed by enzymatically debranching and drying as described inExample 1. DSC thermal analysis of the two samples gave similar meltingpeaks near 103° C., indicative of the presence of amylose-lipid complex.A 15% aqueous dispersion of each sample was prepared by mixing thestarch-emulsifier composition in 30° C. deionized water using a kitchenblender at high speed for 3 minutes. Th-e dispersion was refrigerated at4° C. for 24 hours. Both samples set up as a smooth and opaque pastewith similar rheological characteristics. The sensory evaluation of thetwo samples by trained experts is given in Table 4, where the numbersare scaled from 0 to 10, in which 0 gritty; and 10=smooth forsmoothness; and 10=fiin for body.

TABLE 4 Samples Smoothness Body 5A 7 4.5 5B 7 3

Example 6

Effect of Different Emulsifiers

Emulsifiers, such as glyceryl monostearate, sodium stearoyl-2-lactylate(SSL), sucrose monostearate, sorbitan monostearate, and polyoxyethylenesorbitan monostearate, known to complex with amylose, as well as otheremulsifiers such as enzyme modified lecithin (EML), can be used in thepresent invention to prepare a product as described in Example 1.

SSL increases the viscosity of the jet-cooked material more than otheremulsifiers and tends to form an elastic gel when cooled to 60° C.before debranching. Therefore, lower starch solids and/or higher levelsof (debranching enzyme are preferred when SSL is used. In general,samples made with the aforementioned emulsifiers gave typicalcharacteristics such as small particle size, high opacity, and short,non-elastic paste structure. However differences in the extent of theseproperties do exist with different emulsifiers. For example, theSSL-containing sample was less opaque than samples with otheremulsifiers, and sucrose monosteai-ate gave a much smaller medianparticle size (˜1.5μ) than the typical 4-5μ size. Table 5 summarizessome of the properties of starch-emulsifier compositions prepared usingdifferent emulsifiers.

TABLE 5 Properties Emulsifier Particle Size (μ) Opacity (%)¹ GelRheology² Glyceryl monostearate 5.4 88.8 Short paste Sucrosemonostearate 1.5 88.1 Short paste Sodium stearoyl-2- NM³ 84.2 Viscousgel lactylate ¹Measured at 8% solids. ²Sensory evaluation of 15%refrigerated dispersions. ³Not measured due to high gel viscosity.

Example 7

Co-processing with Gums

Cellulose gum such as carboxymethyl cellulose (CMC) and natural gumssuch as guar, alginate and xanthan gums can be co-processed with thepresent invention to enhance the functional properties of thecomposition. A sample containing 3% glyceryl monostearate was preparedas described in Example 1. An amount of CMC which equals 10% of thestarch solids was prehydrated in water at room temperature to make a 4%CMC dispersion. The dispersion was then mixed into the debranchedstarch-emulsifier composition in a high shear device. The mixture wasthen heated to 90° C. and spray dried into a fine powder. The spraydrier air inlet and outlet temperatures were typically 360° F. (182° C.)and 220° F. (104° C.), respectively. The product gave similar opacitybut higher viscosity compared to the sample without gum.

Example 8

Starch-Emulsifier Composition

A cornstarch slurry (10% solids) containing calcium stearoyl-2-lactylate(2.5% by weight of starch, American Ingredients Co., Kansas City, Mo.)was jet cooked as described in Example 1. The jet cooked dispersion wasthen spray dried under the conditions described in Example 1. A 10%aqueous dispersion of the sample was prepared by mixing the spray driedpowder in 90° C. deionized water using a kitchen blender at high speedfor 3 minutes. The dispersion was cooled at room temperature for 30minutes and then refrigerated at 4° C. for 24 hours (sample 8A).

Another cornstarch slurry (10% solids) containing calciumstearoyl-2-lactylate (2.5% by weight of starch) was prepared by mixingthe cornstarch into predispersed aqueous calcium stearoyl-2-lactylate.The slurry was then autoclaved at 121° C. for 30 minutes followed bycooling at room temperature for 31 minutes. The autoclaved sample wasthen refrigerated at 4° C. for 24 hours (sample 8B). Samples A and Bwere analyzed for firmness using a texture analyzer (TA XT-2, StableMicroSystem). DSC was used to measure the thermal properties of the twosamples. Results from the texture analyzer and DSC measurements areshown in Table 6.

TABLE 6 DSC Peak Firmness Temperature DSC Enthalpy Sample (Peak force,kg) (° C.) (J/g) 8A 0.433 97.0 5.2 8B 3.390 96.4 1.7

Example 9

Effect of Different Emulsifiers on Starch-Emulsifier Complex

Emulsifiers such as glyceryl monostearate, calcium stearoyl-2-lactylateand DATEM esters known to complex with amylose, as well as others, canbe used in the present invention to prepare a product as described inExample 8 (sample 8A). Three 10% refrigerated gels were prepared asdescribed in Example (sample 8A) from three starch-emulsifiercompositions containing equivalent moles (2.5% based on starch weight)of calcium stearoyl-2-lactylate (sample 8A), monoglyceride (sample 9B),and DATEM esters (sample 9C). The samples were evaluated by a textureanalyzer for finness and DSC was used to measure the thermal propertiesof the gels. The results are given in Table 7.

TABLE 7 DSC Peak Firmness Temperature DSC Enthalpy Sample (Peak force,kg) (° C.) (J/g) 8A 0.433 97.0 5.2 9B 0.515 103.8 8.3 9C 0.636 95.9 5.5

Example 10

Potato Starch as Starting Material

A starch-emulsifier composition was made from potato starch andmonoglyceride (2% based on starch weight) according to the methoddescribed in Example 1. A 15% aqueous dispersion of the sample wasprepared as described in Example 2 using a kitchen blender. Sensoryevaluation of the pastes by an expert panel showed that the paste hadhigher viscosity and lower smoothness scores than the cornstarchcounterpart. Molecular weight distribution and thermal properties of thesample wcre measured by HPLC and DSC., respectively. HPLC and DSCresults of the sample along with those of a cornstarch counterpart areshown in Table 8 and 9, respectively.

TABLE 8 HMW LMW % area of Sample Mw Mn Mw Mn LMW Cornstarch 569 kd 119kd 3.6 kd 2.5 kd 35 Potato starch 584 kd  91 kd 4.4 kd 2.6 kd 41

TABLE 9 DSC peak DSC Enthalpy Sample temperature (° C.) (J/g) Cornstarch102.5 7.4 Potato starch 107.1 4.8

Example 1

Reduced-Fat Cake

A 50% reduced-fat cake was prepared with the starch-emulsifier product(3% monoglyceride) prepared according to Example 1 using the followingformulation:

WEIGHT PERCENTAGE STARCH-EMULSIFIER INGREDIENTS CONTROL COMPOSITION Cakeflour 27.63 27.63 Sugar 27.63 27.63 Baking powder 1.38 1.38 Salt 0.550.55 Skim milk 19.61 19.61 Shortening 11.05 5.525 25% Starch-emulsifierpaste 0.00 5.525 Eggs 12.15 12.15

1. Prepare 25% starch-emulsifier paste ahead of time by mixing 25 gramsdried starch-emulsifier composition with 75 grams water andrefrigerating overnight.

2. Cream sugar together with shortening and starch-emulsifier paste inKitchen Aid mixer.

3. Add sifted flour, salt and baking powder.

4. Mix for 1 minute on speed 1.

5. Scrape down sides of bowl and add eggs and milk.

6. Mix for 1 minute on speed 2.

7. Scrape down bowl and mix for 2 minutes on speed 3.

8. Bake at 350° F. (177° C.) for 25-30 minutes.

Table 10 shows the characteristics of the reduced-fat cake compared withthe characteristics of the control.

TABLE 10 Control Starch-emulsifier composition before baking: batterviscosity 4.0 3.5 (1 = low, 5 = high) after baking: height (cm) 4.2 4.3weight (g) 146.93 176.22 10 × 10 cm piece volume (cm³) 420.00 430.00density (g/cm³) 0.3498 0.4098 weight (g) cake 533.85 650.00 sensoryevaluation moist slightly less moist tender slightly less tender uniformcrumb uniform crumb good color less color development good volume

Example 12

50% Reduced-Fat Cream Cheese Spread

A 50% reduced-fat cream cheese spread was prepared with thestarch-emulsifier composition (3% monoglyceride) prepared according toExample 1 using the following formulation:

INGREDIENTS WEIGHT PERCENTAGE Full-fat cream cheese 48.09 25% StarchEmulsifier paste in skim milk 48.57 Pregelatinized starch 2.07 Salt 1.04Cream cheese flavor 0.24

1. Blend 25% starch-emulsifier paste, pregelatinized starch, salt andcream cheese flavor in a Kitchen Aid mixer until smooth.

2. Add full-fat cream cheese and blend until homogenous.

3. Fill into receiving container and refrigerate.

Example 13

Fat-Free Onion Dip

A fat-free onion dip was prepared with the starch-emulsifier composition(3% monoglyceride) prepared according to Example 1 using the followingformulation:

INGREDIENTS WEIGHT PERCENTAGE 15% Starch-emulsifier gel in skim milk91.84 Dried onions 5.29 Hydrolyzed corn protein 0.91 Salt 0.64 15×Starter dist. replacer 0.50 Xanthan gum 0.26 Sour cream flavor 0.24Citric acid 0.32

1. Blend 15% starch-emulsifier gel, starter distillate and xanthan gumwith low shear until smooth.

2. Add corn protein, sour cream flavor, salt and citric acid and blenduntil homogenous.

3. Blend in dried onions until evenly distributed.

4. Pack and refrigerate.

Example 14

Skim Milk

A skim milk was prepared with the starch-emulsifier composition(containing 3% sucrose stearate) according to Example 6 using thefollowing formulation:

INGREDIENTS WEIGHT PERCENTAGE Skim milk 97.990 Starch-emulsifier powder2.000 Carrageenan (FMC, Viscarin GP 109) 0.010

1. Slowly add the starch-emulsifier powder to 116° F. (71° C.) milkwhile mixing with a kitchen blender (high speed). Continue mixing forthree minutes once dispersed.

2. Add carrageenani and mix for 1 minute.

3. Homogenize through a two-stage homogenizer (2500/500 psi).

4. Cool in ice/water bath in capped bottles to 50° F. (10° C.), shakeintermittently.

5. Store refrigerated.

The milk prepared as described above was compared to skim milk and wholemilk. The sensory evaluation was conducted by a three-person trainedexpert panel, and the results are given in Table 11.

TABLE 11 Hunter Mouth Opacity¹ Viscosity Smoothness (1:10 (9 = more (9 =more Formulation dilution) viscous) Viscosity (cP)² smooth) 2% starch-63% 4 16 8.5 emulsifier product skin milk 50% 4 13 8.5 whole milk 84% 916 9 ¹= measured according to Example 2D ²Zahn cup #2

Example 15

Preparation of No-Fat Ice Cream

A no-fat ice cream was prepared with the starch-emulsifier-gumcomposition prepared according to Example 7 using the followingformulation:

INGREDIENTS WEIGHT PERCENTAGE Skim Milk 72.52 Corn Syrup Solids - 36DE12.15 Sugar 2.60 Nonfat Dry Milk 6.47 Maltodextrin - 10DE 4.55 Powder(Example 7) 1.20 Stabilizer Polmo (Germantown) 0.31 Mono-diglycerides,Gold Star Swan 0.20 (Grinstad)

1. Funnel feed the dry ingredients, as a blend, into a recirculatingstream of skim milk.

2. Preheat to 150° F. (65° C.) and homogenize through a 2 stagehomogenizer; 2000 PSI (1 st stage), 500 PSI (2nd stage).

3. Pasteurize at 185° F. (85° C.) for 25 seconds.

4. Age overnight at 40° F. (4° C.).

5. Add pure vanilla extract (2×) at 0.6% use rate, then freeze to 20° F.(−6° C.) with a continuous freezer (target 75% overtin).

6. Harden at −30° F. (−32° C.) for 24 hours (for quart size containers).

Example 16

Preparation of No-fat Mayonnaise

A no-fat mayonnaise was prepared with the debranched starch-emulsifiercomposition (containing 2% monolyceride) prepared according to Example 1using the following formulation:

INGREDIENTS WEIGHT PERCENTAGE Water 65.39 Vinegar (50 gr, white dist.)10.80 Sugar, granulated cane 4.50 Corn syrup solids (Frodex 24) 4.50Powder (Example 1) 4.20 Corn starch Pregelatinized cornstarch 3.00 EggYolks (frozen) 2.50 Soybean oil 2.30 Salt 2.00 Xanthan gum (Keltrol F)0.40 Lemon juice concentrate 0.20 Potassium sorbate 0.10 Sodium benzoate0.10 β-carotene 0.01 TOTAL 100.00

Procedure:

1. Place water (185° F.; 85° C.) in glass vessel of a kitchen blender.

2. Disperse dcbranched starch-emulsifier composition and corn starch asa dry blend. Slowly add the powders to the kitchen blender while mixingon maximum speed. Once dispersed, blend on high for 5 minutes to fullyhydrate.

3. Add dry blend of xanthan, corn syrup solids, sugar and salt tokitchen blender, blend on high for 2 minutes, to fully disperse.

4. Transfer contents to a mini food processor, add egg yolk, color,acids and lemon juice, then process just enough to mix all ingredients.

5. Add oil, slowly, while mixing. Continue mixing for 1-2 minutes untilproduct is smooth and homogeneous in appearance.

6. Fill containers, refrigerate overnight before evaluation.

Example 17

Preparation of Reduced-Fat Peanut Butter Spread

A reduced-fat peanut butter spread was prepared with the debranchedstarch-emulsifier composition (containing 2% monoglyceride) preparedaccording to Example 1 using the following formulation:

INGREDIENT WEIGHT PERCENTAGE Water 49.01 Peanut Butter (Skippy Full-Fat)25.00 Maltodextrin (GPC M040) 15.00 Sucrose 2.50 Powder (Example 1) 4.50Glycerin 2.00 CMC (Aqualon 7MF) 0.50 Salt 0.50 Roasted Peanut Flavor(Bell #109-14081) 0.29 Potasium sorbate (granular) 0.10 Caramel Color(Williamson #622) 0.60 TOTAL 100.00

Procedure:

1. Place ambient temperature water in glass vessel of a standard kitchenblender.

2. Slowly add starch-emulsifier composition and CMC (as a dry blend)while mixing on maximum speed. Mix for 5 minutes to fully hydrate.

3. Add sucrose, M040, salt, K sorbate (as a dry blend) and continueshear for 5 minutes.

4. Add premelted peanut butter, glycerin and color and continue mixingat medium speed for 1 minute. Transfer to a metal container; place in aboiling water bath (185-190° F.; 85° C.−88° C.), and homogenize using aSilverson homogenizer at ¾ maximum speed for 5 minutes (small emulsorscreen). Add flavor last. 5. Place in ice water bath and cool to 80° F.(27° C.) while slowly mixing with an overhead stirrer. MeasureBrookfield viscosity at 80° F. (27° C.).

6. Deacrate using a WhipMix dearator.

7. Store refrigerated 2 to 3 days before evaluating.

Example 18

Fat Free Chocolate Spread

A fat free chocolate spread was prepared with the debranchedstarch-emulsifier composition (containing 2% monoglyceride) preparedaccording to Example 1 using the following formulation:

INGREDIENT WEIGHT PERCENTAGE Maltodextrin M040 18.00 Water 50.56 HeavyCream 7.90 Cocoa Powder (Bensdorp defatted) 3.50 Powder (Example 1) 4.50Xanthan Gum (Keltrol F) 0.04 Salt 0.50 Fructose (Krystar 300) 15.00TOTAL 100.00

Procedure:

1. Prepare blend of dry ingredients.

2. Slowly disperse blend into 195-200° F. (90-94° C.) water with astandard kitchen blender.

3. Blend on high speed for 5 minutes.

4. Add cream. Continue blending for 1 minute.

5. Deaerate using WhipMix deaerator.

6. Store refrigerated 2 to 3 days before evaluating.

Example 19

Water and Oil Absorption

The water absorption (percent by weight) was determined by amodification of American Association of Cereal Chemists Method 88-04.Instead of using 5 grams of test sample and centrifuging at 2000 g, 3grams of sample were dispersed in water and centrifuged at 1450 g. Foroil absorption, store-bought Wesson vegetable oil was used in lieu ofwater. Table 12 shows the water and oil absorption results for thestarch-emulsifier composition (Example 1, sample C.). Data for adebranched starch (Example 1, sample A) and a microcirystallinecellulose (Avicel PH105, FMC.) are also presented for comparison.

TABLE 12 Water Absorption Oil Absorption Sample (%) (%)Starch-emulsifier 132 71 composition Debranched starch 211 86Microcrystalline cellulose 213 137

Those skilled in the art will recognize or be able to ascertain, usingno more than routine experimcntation, many equivalents to the specificembodiments of the invention described herein. Such equivalents areintended to be encompassed in the scope of the following claims.

I claim:
 1. A method for preparing a starch-emulsifier composition,comprising the steps of: a) heating a mixture of starch and anemulsifier in an aqueous medium under conditions sufficient to disruptessentially all starch granules and solubilize amylose and amylopectinin the starch, to produce a dispersion of starch and emulsifier, whereinthe emulsifier is enzyme modified lecithin; and b) optionally treatingthe starch in the starch and emulsifier dispersion to produce a starchcontaining greater than about 20% short chain amylose, thereby producinga starch-emulsifier composition.
 2. The method of claim 1, wherein step(b) is performed by enzymatic treatment or acid treatment or combinationthereof.
 3. The method of claim 2, further comprising: c) heating theproduct of step (a) or (b) to a temperature sufficient to solubilize theemulsifier; and d) optionally drying the product of step (c).
 4. Themethod of claim 1 wherein step (b) is performed using a debranchingenzyme or amylase or combination thereof.
 5. The method of claim 1,further comprising drying the starch-emulsifier composition.
 6. Themethod of claim 5, further comprising adding a hydrocolloid, gum,polymer, modified starch or combination thereof.
 7. The method of claim6, wherein the hydrocolloid, gum, polymer or modified starch is selectedfrom the group consisting of xanthan gum, alginate carraglenan,carboxymethyl cellulose, methylcellulose, guar gum, gum arabic andlocust bean gum.
 8. The method of claim 1, further comprising anemulsifier selected from the group consisting of monoglycerides,sorbitan esters, diacetyl tartaric acid esters of monoglycerides,propylene glycol esters, polysorbates and sucrose esters of medium andlong chain saturated fatty acids and combinations thereof.
 9. The methodof claim 8, wherein the emulsifier is selected from the group consistingof glyceryl monostearate, polyethylene glycol monolaurate, calciumstearoyl lactate, sodium stearoyl lactate polyoxyethylene sorbitanmonostearate, sucrose monopalmitate and sucrose monostlarate.
 10. Themethod of claim 1, wherein the starch has an amylose content of lessthan about 30%.
 11. The method of claim 10, wherein the starch isselected from the group consisting of cornstarch, potato, tapioca,wheat, smooth pea, rice, sago, barley and oat.
 12. The method of claim1, wherein the amount of emulsifier is from about 0.1% to about 25% byweight.
 13. The method of claim 12, wherein the amount of emulsifier isfrom about 1% to about 10% by weight.
 14. The method of claim 1, furthercomprising adding a hydrocolloid, gum, polymer, modified starch orcombination thereof.
 15. The method of claim 14, wherein thehydrocolloid, gum, polymer or modified starch is selected from the groupconsisting of xanthan gum, alginate carrageenan, carboxymethylcellulose, methylcellulose, guar gum, gum arabic and locust bean gum.16. The method of claim 1, wherein step (a) is performed by jet cooking.17. A method for preparing a starch-emulsifier composition, comprisingthe steps of: a) heating a starch under conditions sufficient to disruptessentially all starch granules and solubilize amylose and amylopectinin the starch; b) immediately combining the product of step (a) with anemulsifier to produce a dispersion of starch and emulsifier, wherein theemulsifier is enzyme modified lecithin; and c) optionally treating thestarch in the starch and emulsifier dispersion to produce a starchcontaining greater than about 20% short chain amylose, thereby producinga starch-emulsifier composition.
 18. The method of claim 17, whereinstep (c) is performed by enzymatic treatment or acid treatment orcombination thereof.
 19. The method of claim 17, further comprising anemulsifier selected from the group consisting of monoglycerides,sorbitan esters, diacetyl tartaric acid esters of monoglyclrides,propylene glycol esters, polysorbates and sucrose esters of medium andlong chain saturated fatty acids and combinations thereof.